Six Sigma Black Belt

Carl F. Berardinelli

**** ******** *****, ****** **** 45365

Home: 937-***-**** Mobile: 765-***-****

acp7sy@r.postjobfree.com

LinkedIn Public Profile

www.linkedin.com/pub/carl-berardinelli/a/ba4/868/

PROFESSIONAL EXPERIENCE

Crown Equipment, New Bremen, Ohio 2014 to Present

Black Belt

Develop and facilitate training for yellow, green and black belts. .

Facilitate seminars for sponsors and champions.

Engage project sponsors throughout the project e.g. selection, scoping, gate reviews and progress updates.

Train other relative subject matter as required (Minitab, MSA, SPC, Control Methods, etc.).

Provide project coaching to Six Sigma belt candidates.

Apply project management methods to manage six sigma performance and progress.

Reports to senior management on the performance of Six Sigma.

Lead and manage projects.

Mentor Yellow, Green and Black belts in using the DMAIC process to complete projects.

Assist in removing project road blocks.

Schedule and execute project gate reviews.

Assess risks associated with tests and solutions, e.g. efficiency and effectiveness.

Verify project impact to performance, cost, quality, yield, sigma, etc.

Ensures project solutions are fed back into the quality management system

Mayo Clinic, Rochester Minnesota 2008 to 2014

SENIOR PRINCIPAL HEALTH SYSTEMS ENGINEERING ANALYST

Provided consultative services at an institutional level to departments/divisions and committees from any Mayo entity requesting assistance with planning, development, implementation, evaluation and/or improvement of clinical, administrative, and/or operational systems, processes and procedures.

Utilized Root Causes Analysis while assisting Sentinel events investigations.

Taught and used Fault Tree and Causal Tree analysis.

Taught and used graphical analysis including Multi-Vari and Control charts.

Delivered analysis, recommendations, and project management

Developed and administered the Mayo Clinic Gold Quality Fellows program.

Responsible for facilitation of continuous improvement efforts.

Faculty Member with the Quality Academy College of Medicine, Mayo Clinic

Applied various improvement methodologies (Lean, Six Sigma, Design for Six Sigma, & Human Factors).

Taught Improvement methodologies.

Taught Applied Statistics.

Developed design of experiments courses.

Developed Black Belt level Lean Six Sigma training.

Developed Design for Six Sigma training.

Served as the statistics expert in Quality Management Services.

Part of a two person team that re-wrote all of Mayo Clinic’s Teams Training materials.

Mentored Quality Fellows, Medical Students and Medical fellows in quality and process improvement methods.

Serve as the lead Quality Improvement Advisor for priority projects.

One of two Mayo Clinic’s representatives on The Joint Commissions Center for Transforming Healthcare collaborative on patient handoff communication.

Served on the Quality Review Board to grant maintenances or certification part four (QI) for physicians

Wrote Mayo Clinic’s Gold level quality fellows test. This level is equivalent to black belt level.

Served on the Mayo Quality Fellows Certification team.

Member of the Enterprise Portfolio Management Office workgroup.

Delphi Electronics and Safety, Kokomo Indiana 1990 to 2008

SENIOR PROJECT ENGINEER

Lead for Six Sigma, Robust Engineering & Shainin Projects. Individual project savings ranged from 10’s of thousands to millions of dollars averaging $882k per project.

Conducted Six Sigma Green Belt and Black Belt training.

Coached Robust Engineering teams mentored individual Black Belts and Green Belt teams.

Developed Fine Pitch (.008”) Flip Chip assembly process into demonstration, including reliability testing.

Designed & Developed Electronic Test & Control systems to meet project & standards & requirements.

Served as Manufacturing Engineering Start Center Leader for Restraint system. Responsible for manufacturing related portions of new business quotes.

Designed, implemented, & procured equipment for production of Powertrain & Restraint Systems controls.

Specified process equipment for SMT, odd form, and final assembly.

Designed manufacturing plans, manufacturing control plans and pFMEA for automotive electronics.

Worked with planning to select manufacturing locations and determine associated capitol and conversion cost.

Participated as a member of multiple design teams to insure that new product designs were manufacturable, functional and cost effective utilizing DFA/DFM concepts.

Supported these designs from concepts through start of production. Worked closely with Quality Engineering.

Worked with inside and outside suppliers to develop process equipment and materials.

Served as an active member of the Powertrain Control Module packaging team.

Participated as an active member of the Process Center of Expertise on wave soldering.

Lead the Wave Solder Pallet Process Center of Expertise.

Developed a composite material wave solder pallet used throughout Delco.

ADDITIONAL EXPERIENCE

Designed, implemented, and procured equipment for production areas.

Developed Capital and Labor Estimates for projects.

Designed manufacturing control plans.

Recommended and implemented product design changes.

Interacted with equipment and parts vendors.

Coordinated the efforts of four other Engineers who were working on various projects.

Successfully designed and implemented test and alignment equipment, for color television.

Designed Measurement circuits, interface circuits and configured for measuring color temperature, focus (optical), focus voltage, and HIPOT for color television.

Developed test equipment calibration, correlation, and preventative maintenance procedures.

Wrote test specifications for new products that were to be test automatically.

Developed schedules and estimated costs for new automation projects.

Supervised technicians during the construction of new Automatic Test Equipment.

Sample Projects

DFSS Methodology to design a laser transmission welding process of polymer case and cover

oShared injection-mold tooling with two competitors, No product design changes, The customer required laser transmission welding, Limited experience in laser welding of polymers, Relatively new technology, varying and contradictory philosophies among equipment suppliers and literature.

oDeliverables from the project charter were Technology selection, Equipment selection, Process parameters identification, optimization and tolerancing, capability estimates, Monitoring plan, Quality plan.

oUsed HOQ, Ideal Function, Transfer function score card, Pugh concept selection, functional Process map, Sequential experimentation including RSM, Process Mapping, FMEA, Monte Carlo Simulation, Capability Analysis.

oThe three top KPOV resulting capabilities 5.3 Cpk,3.1 Cpk,7.1 Cpk…

o$1.06M capitol savings.

o$57K per year scrap savings.

PODS-B Test failure reduction at customer site

oProcess yield 88% at the customer who is ready to pull the business. Our company supplied both the sensor and the end of line test equipment.

oUsed, Ideal Function, functional Process Map, Sequential Experimentation, Process Mapping, FMEA, Yield Analysis, and Lean Concepts.

o Yeild improvement to 99.8% without additional equipment, improved flow through test which improved efficiency and maintained a consistent product temperature at test.

o $360,000 in capitol and $720/defective charge back saved.

o The business save was worth $100M.

Patient Handoff Communication

oThe handoff between units is dangerous for the patient and results in sentinel events.

oUtilized quality Kano style surveys to understand sender and receiver needs, function deployment to arrive at functional and process requirements, in sitsu simulation to confirm approach (total separation, reduction in time), validated a manual method across ED, MICU, and a medical unit. Confirmed with high statistical and practical significance.

oShared results with the other major academic medical centers.

oIssued requirement to IT for an automated method.

Venous Thromboembolism Prophylaxis (VTE-P)

oVTE is considered to be the most common preventable cause of hospital death in the United States, and the third most common cause of all hospital-related deaths.

oAt baseline we found appropriate VTE prophylaxis in 79.2% of patients, and use of VTE prophylaxis tollgates in 62% of candidate order sets at baseline. After baseline measures, we verified causes of defects by direct review, categorizing according to failure to use.

oNearly all defects occurred in clinical areas not served by tollgate bearing order sets. This served as information for discussion of local adaptations and acceptance of VTE prophylaxis tollgates.

oAt 7 months, 100% of all key order sets had the VTE prophylaxis tollgate inserted. There was a concurrent improvement in appropriate VTE prophylaxis to 93.6% without increase in the countermeasures (bleeds, postponed procedures).

oAfter deploying the clinical decision support tools (the rate of appropriate VTE prophylaxis further improved to 96.8%.

oAt the close of the spread project, there was a statistically significant improvement in appropriate VTE prophylaxis to 98.4 %.

o$2M annualized cost savings, minimum of six lives per years saved.

Eliminate undersized chain anchor welds

oHardy perennial line stop issue.

oOptimized weld process using DoE

oImplemented a robust process that is nearly impossible to create an undersized weld.

oImplemented a control system that includes monitoring of welder setting and sampling of weld sizes.

oIssue eliminated.

Inadvertent engagement of horn button on truck control joystick.

oThe issue was producing scrap and field returns for > 15 years.

oComponent Swap pointed to interaction between 3 components.

oThrough dimensional analysis inconstancy in cad models were identified.

oCorrect the models and injection molds accordingly.

oManaged and implemented the low risk economical change.

oIssue eliminated.

EDUCATION

Bachelor of Science, EET Indiana State University

Six Sigma Black Belt (ASQ Certification15659), Six Sigma Master Black Belt (AIT)

Robust Engineering Practitioner, Robust Engineering Coach

Shainin Apprentice, Shainin Journeyman

Design for Six Sigma Black Belt, Design for Six Sigma Master Black Belt

Mayo Clinic Bronze, Silver, and Gold Quality Fellow

Additional Education

Quality Engineering I, II, III, IV (4 Semesters)

Reliability Engineering I, II (2 Semesters)

Lean Concepts

Time Motion Analysis

Project Management

Design for Manufacturing / Design For Assembly ( DFM / DFA)

Geometric Dimensioning and Tolerancing (GD&T)

Wave Soldering Workshop

Encapsulation of Electronic Devices

Applied Robotics

Financial Fundamentals

Succeeding with Diversity

Determining Effective Fatigue Life in Electronic Assemblies

PATENTS

6,259,608, Conductor Pattern for Surface Mount Devices and Methods Therefore.

6,531,664, Surface Mount Devices with Solder,

Two patents pending concerning fine and ultra-fine pitch flip chip process

Defensive Publications 433008: Laser Defined Solderable Area for Circuit Boards.

Defensive Publication 517068: Stepped Laser Welding Tool for Laser Plastic through Transmission Welding

PUBLICATIONS

Ron Santos Baseball’s Hall and a Lesson in Desirability. www.isixsigma.co

DFSS Lights the Way, ASQ Six Sigma Magazine, vol. 8 issue 3 - May 2009

Electrical Resistance as a Response for Solder Joint Experimentation, Delphi Techcon 2004

Robust Optimization of a Lead Free SMT Process, Delphi Techcon 2004

Dynamic Optimization of Lead Free Reflow Solder Process, Taguchi Symposium 2004 (presented & published in the proceedings)

Selective Solder Optimization using Electrical Resistance as a Response, Taguchi Symposium 2006 (presented & published in the proceedings)

Using a Framework for Spread of Best Practices to Implement Successful Venous Thromboembolism Prophylaxis Throughout a Large Hospital System, American Journal of Medical Quality (American Journal of Medical Quality 1062860611411518, first published on August 10, 2011 as doi:10.1177/1062860611411518)

To DMAIC or Not to DMAIC? Identify when you need a structured method for problem solving

Quality Progress (ISSN 0033-524X) (published monthly by the American Society for Quality, 600 N. Plankinton Ave., Milwaukee, WI 53203 first published November 2012, Vol. 45/No.11)

A Guide to Control Charts http://www.isixsigma.com/tools-templates/control-charts/a-guide-to-control-charts

Multivariate Control Charts: T2 and Generalized Variance http://www.isixsigma.com/tools-templates/control-charts/multivariate-control-charts-t2-and-generalized-variance/

PRESENTATIONS

Handoff Communication, Institute for Clinical Systems Improvement/Institute for Healthcare Improvement, St. Paul, Minnesota 09/2006

Selective Solder Optimization Using Electrical Resistance as a Response, Taguchi Symposium 2006, Ann Arbor, Michigan 09/2006

Venous Thromboembolism (VTE) Prophylaxis Spread, Mayo Quality Conference, Rochester, Minnesota 03/2011

Venous Thromboembolism (VTE) Prophylaxis Spread, Minnesota Alliance for Patient Safety, Brooklyn Center, Minnesota 11/2010

AWARDS

General Motors Presidents Council Award

Innovation and Continuous Improvement Methodologies (I&CIM) Master

Manufacturing Engineering Excellence Award

Delphi Excellence Award for excellence in engineering

International Quality and Productivity Center’s Best Design for Six Sigma Project 2008

RCA Quality Leadership Award

Mayo Clinic Teamwork Excellence Award (2)

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